CA2920956C - Molded wall unit including a corner bracket - Google Patents

Abstract

A bathroom wall unit includes a molded wall panel formed of a polymer and defining a recessed pocket. A flexible substrate supporting mosaic tiles is illustratively coupled to a rear wall of the recessed pocket. Surface treatment is illustratively provided within linear indentations in the wall panel to simulate grout lines. A corner bracket illustratively includes first and second trios of arms supporting seals and defining first, second, and third recesses for receiving mounting flanges of a pair of wall panels and a locking device of an inner sealing body to provide additional seals with the wall panels.

Description

MOLDED WALL UNIT INCLUDING A CORNER BRACKET
Background and Summary [0001] The present invention relates generally to molded wall panels and, more particularly, to molded wall panels with connecting brackets for use in bathroom tub and shower installations.

[0002] It is well known to provide tub and shower wall panels molded from a polymer to simulate ceramic tile. More particularly, such wall panels typically include indentations between adjacent rectangular raised portions to simulate grout lines between adjacent tiles. However, such molded wall panels often fail to closely resemble ceramic tiles with conventional grout lines. Additionally, such molded wall panels typically provide a limited number of design options.

[0003] Consumers would like to have the ability to customize their tub and shower walls, but often cannot afford a complete tile installation. While many consumers would prefer to have ceramic tile installations, this is often prohibitive due to cost and installation time.

[0004] As such, it is desired to provide cost effective, molded wall panels that more closely resemble the appearance of traditional ceramic tile and authentic grout lines, and that are simple to install. Additionally, it is desired to provide such molded wall panels that include a variety of design options that may be customized by the user.

[0005] According to an illustrative embodiment of the present disclosure, a corner bracket for a shower enclosure includes an outer receiver including an outer receiver body defining first outer recess configured to receive a first wall panel, a second outer recess configured to receive a second wall panel, and a center recess positioned intermediate the first outer recess and the second outer recess. An insert is operably coupled to the outer receiver, the insert including an inner sealing body received within the center recess of the outer receiver body. A locking device is supported by the outer receiver body and the inner sealing body, the locking device configured to secure the inner sealing body to the outer receiver body.

[0006] According to another illustrative embodiment of the present disclosure, a corner bracket for a shower enclosure includes an outer receiver coupled to a first mounting stud and a second mounting stud. A body of the outer receiver is formed of a first material and includes a first inner arm, a first middle arm, and a first outer arm. The body also includes a second inner arm, a second middle arm, and a second outer arm. The first outer arm and the first middle arm define a first recess, the second outer arm and the second middle arm define a second recess, and the first inner arm and the second inner arm define a third recess. Both the first inner arm and the second inner arm have a plurality of raised surfaces extending into the third recess. The corner bracket also includes a first wall panel received within the first recess, a second wall panel received within the second recess, and an inner sealing body including a locking device that is received within the third recess and coupled to the body by the plurality of raised surfaces.

[0007] In a further illustrative embodiment of the present disclosure, a method of forming a bathroom wall unit includes the steps of mounting a corner bracket to a wall stud, coupling a first wall panel to the corner bracket within a first recess of the corner bracket, and coupling a sealing body to the corner bracket and the first wall panel such that a fluid tight seal exists at the interface of the first wall panel and the sealing body.

[0008] Additional features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrative embodiment exemplifying the best mode of carrying out the invention as presently perceived.
Brief Description of the Drawings

[0009] The detailed description of the drawings particularly refers to the accompanying figures in which:

[0010] FIG. 1 is a perspective view of an illustrative shower enclosure including wall units of the present disclosure;

[0011] FIG. 2 is a perspective view, with partial cut-aways, of a wall unit of FIG. 1;

[0012] FIG. 3 is an exploded perspective view, with partial cut-aways, of the wall unit of FIG. 2;

[0013] FIG. 4A is a flow chart of an illustrative method of manufacturing the wall unit of FIG. 2;

[0014] FIG. 4B is a flow chart of an illustrative casting method of FIG.
4A;

[0015] FIG. 5 is a perspective view of a further illustrative shower enclosure including wall units of the present disclosure;

[0016] FIG. 6 is an exploded perspective view of the shower enclosure of FIG. 5;

[0017] FIG. 7 is a perspective view of the top corner between the wall units of FIG. 5;

[0018] FIG. 8 is an exploded perspective view of the top corner of FIG. 7;

[0019] FIG. 9 is a top plan view of the top corner of FIG. 7;

[0020] FIG. 10 is a perspective view, in partial cross-section, of the upper end of the corner bracket of FIG. 7;

[0021] FIG. 11 is a top plan view of a further illustrative corner bracket for use with the shower enclosure of FIG. 5;

[0022] FIG. 12 is an exploded perspective view of a further illustrative corner bracket for use with a shower enclosure;

[0023] FIG. 13 is a cross-sectional view of the corner bracket of FIG.12 as used in a shower enclosure;

[0024] FIG. 14 is a cross-sectional view of the outer receiver of the corner bracket of FIG. 12 as used in a shower enclosure;

[0025] FIG. 15 is a cross-sectional view of the outer receiver of a corner bracket of FIG.
14 with mounted wall panels coupled thereto; and

[0026] FIG. 16 is a cross-sectional view of an inner sealing body being inserted into the outer receiver of the corner bracket of FIG. 12 in a shower enclosure.
Detailed Description of the Drawings

[0027] The embodiments of the invention described herein are not intended to be exhaustive or to limit the invention to precise forms disclosed. Rather, the embodiments selected for description have been chosen to enable one skilled in the art to practice the invention.

[0028] Referring initially to FIG. 1, a shower enclosure 10 including illustrative bathroom wall units 12a, 12b of the present disclosure is shown. The shower enclosure 10 supports a faucet 14 for controlling water flow through a showerhead 16. The wall units 12a, 12b are illustratively supported by a wall 18 including mounting studs 20.
While the wall units 12 are shown for use with a shower enclosure 10, it should be appreciated that the wall units 12 may be used in a variety of installations, such as in connection with bath tubs, vanities and kitchens.

[0029] With reference to FIGS. 1-3, each wall unit 12 includes a molded wall panel 22 including a front surface 24, a rear surface 26, a first side edge 28, a second side edge 30, an upper edge 32 and a lower edge 34. The front surface 24 and the rear surface 26 extend between the first and second side edges 28 and 30. The front and rear surfaces 24 and 26 also extend between upper and lower edges 32 and 34.

[0030] The molded wall panel 22 may be formed from a polymer, illustratively a thermoplastic such as acrylonitrile butadiene styrene (ABS). In certain illustrative embodiments, the front surface 24 may be generally smooth or planar. In other illustrative embodiments, a plurality of linear indentations 36 may be formed in the front surface 24. In such embodiments, a plurality of raised portions 38, illustratively of a polygonal shape, are formed intermediate the linear indentations 36. The linear indentations 36 are configured to simulate grout lines, while the raised portions 38 are configured to simulate conventional ceramic tile.

[0031] The linear indentations 36 illustratively include a plurality of horizontal indentations 36a and a plurality of vertical indentations 36b. As such, the raised portions 38 are illustratively of a rectangular shape. In one illustrative embodiment, the raised portions 38 are squares, such as 4 inch x 4 inch squares or 6 inch x 6 inch squares to simulate conventional ceramic tile dimensions. The polymer of the wall panel 22 may also be capped with a patterned film (e.g., marble, etc.) to create a more realistic tile-like appearance.

[0032] In the illustrative embodiment, a recessed pocket 40 is formed within the wall panel 22. The recessed pocket 40 illustratively includes a rear wall 42, a bottom wall 44 and a top wall 46. The recessed pocket 40 illustratively has a depth (d) of approximately 0.38 inches to receive conventional ceramic tiles, such as a mosaic tile assembly 50. The tile assembly 50 illustratively includes individual ceramic tiles 52 of conventional size and shape, as further detailed herein. While ceramic tiles are illustratively used in the tile assembly 50, other materials may be substituted therefor, such as glass or stone.

[0033] The height (h) of the recessed pocket 40 may vary depending upon the size, shape and number of mosaic tiles 52 to be inserted within the pocket 40. In an illustrative embodiment, the height (h) of the recessed pocket 40 is between 3 inches and 6 inches.
Illustratively, the pocket 40 has a height (h) of approximately 6 inches to facilitate insertion of conventional mosaic tile sheets (typically 12 inches by 12 inches). The mosaic tile sheets would illustratively be cut in half to a length of 12 inches and a height of 6 inches for insertion within the pocket 40.

[0034] Illustratively, the pocket 40 extends the full width of the wall panel 22 between the first and second side edges 28 and 30 (i.e., open ends). In alternative embodiments, the pocket 40 may not extend the full width of the wall panel 22 and terminate prior to one or both of the side edges 28 and 30 (i.e., closed end(s)).

[0035] Illustratively, the mosaic tiles 52 are supported on a flexible substrate, such as a mesh backing 54. The mesh backing 54 and tiles 52 are adhered to the rear wall 42 of the recessed pocket 40 through conventional means, such as an adhesive 56. Once in position, a finish grout 58, such as an acrylic, may be used to fill in the gaps between adjacent mosaic tiles 52. The tile assembly 50 may be provided with the wall panel 22 as a kit.
Alternatively, the tile assembly 50 may be acquired separately by the installer to facilitate customization as desired by the end user.

[0036] Reinforcing ribs 60 may be supported by the rear surface 26 of the wall panel 22 to further support the wall panel 22 and provide additional rigidity. The ribs 60 may be spaced at various locations to align with mounting studs 20. In one illustrative embodiment, the ribs 60 may be integrally molded with the wall panel 22. Inserts 62, such as Styrofoam panels may be coupled to the rear surface 62 of the wall panel 22 for additional support through contact with wall studs 20. In one illustrative embodiment, the inserts 62 may be positioned intermediate the ribs 60.

[0037] In certain illustrative embodiments, inwardly extending pockets may be formed within the linear indentations 36 of the wall panel 22 to receive conventional grout (not shown).
For example, the installer may fill the pockets with grout in a manner similar to conventional ceramic tile.

[0038] In other illustrative embodiments, simulated grout 64 may be formed within the front surface 66 of linear indentations 36 between adjacent raised portions 38 in the wall panel 22. More particularly, the linear indentations 36 may be surfaced treated in order to provide for the appearance of simulated grout 64. As further detailed herein, in one illustrative embodiment the surface 66 is treated through a laser etching process. In another illustrative embodiment, the surface 66 is treated through a sand blasting process. In yet another illustrative embodiment, a polymeric colored film may be applied to the surface 66 to define the simulated grout 64.

[0039] In the laser etching process, the surface 66 of linear indentations 36 are etched with a laser to turn the simulated grout 64 a different color. The settings of the laser (e.g., intensity, duration) may be modified or varied to obtain different colors of the simulated grout 64. For example, the simulated grout 64 may be gray, brown or black depending upon the laser settings. Additives may be added to the polymer of the wall panel 22 to cause the laser to change the simulated grout 64 to a variety of different colors, such as red, blue, etc. Additionally, the laser may be adjusted to create textures within the polymer of the wall panel 22. In other words, the surface 66 may be roughened by the laser in order to provide a grout-like texture.

[0040] In the sand blasting process, a sand or bead blast is utilized to create a grout pattern in the linear indentations 36 of the wall panel 22. Areas of the wall panel 22 that should not be affected (e.g., raised portions 38) may be masked with a fixture. The sand or beads etched/embed within the polymer of the indentations 36 and turn it to a different color. By changing the color of the sand, different grout colors may be provided (e.g., black, gray, brown, etc.). The size of the sand/bead grains may also be adjusted to create different textures.

[0041] With reference to FIGS. 1, 4A and 4B, in an illustrative method of manufacturing 100, the wall panel 22 is formed at block 102, illustratively through applying a thermoplastic, such as ABS, within a mold. The wall panel 22 is molded to define the linear indentations 36 and raised portions 38, along with the recessed pocket 40. In one illustrative embodiment, the wall panel 22 may be molded through a thermoforming process.

[0042] With reference to the illustrative panel molding process of FIG.
4B, the mold for forming the wall panel 22 may be formed by using a traditional ceramic tile assembly or wall as a pattern or template. More particularly, at block 112 a ceramic tile assembly or wall is illustratively formed by setting and grouting individual ceramic tiles on a horizontal support surface. A mold is illustratively cast at step 114. More particularly, a fluid material, such as a resin, urethane, aluminum, etc. is cast over the finished ceramic tile assembly at block 114a. The fluid material then sets or hardens at block 114b. The ceramic tile assembly is removed from the set or hardened material at block 114c. The resulting "negative" impression defined by the set material defines a mold used for forming the wall panel 22. Any additional desired details (e.g., recessed pocket 40) may be created within the mold, illustratively through machining, at block 114d.

[0043] In an illustrative thermoforming process at block 116, the wall panel 22 is formed from polymer applied to the mold to capture the shape, form and texture (including surface irregularities and/or cavities) of the ceramic tile assembly. The result is a formed wall panel 22 that looks like the original pattern with all of the irregularities or imperfections of the ceramic tile assembly, including the tiles, grout and the human interaction in laying the tile.

[0044] At block 104 of FIG. 4A, surface treatment is applied to the front surface 66 of linear indentations 64 to define simulated grout 64. Such surface treatment may be sand blasting and/or laser etching, as further detailed herein.

[0045] At block 106 of FIG. 4A, adhesive 56 is applied to the rear wall 42 of the recessed pocket 40 and the tile assembly 50 is secured to the rear wall 42. At block 108, finish grout 58, such as acrylic, may be applied to the tile assembly 50 after it has set to the rear wall 42.

[0046] The rear surface of the wall panel 22 illustratively includes mounting members, such as the ribs 60, to bring the panel 22 equal to the wall studs 20 for direct mounting to the studs 20. A hole may be drilled through the rear wall 42 of the recessed pocket 40 at the center of the stud 20. The wall panel 22 is then secured to the stud 20 to provide additional rigidity to the recessed pocket 40. A silicone is illustratively applied to seal the opening. Conventional mounting flanges proximate upper and lower edges 32 and 34 may receive fasteners to secure the wall panel 22 to wall studs 20.

[0047] With further reference to FIGS. 5-10, a further illustrative shower enclosure 210 is shown as including many similar components as the shower enclosure 10 detailed above. As such, similar components will be identified with like reference numbers. The illustrative shower enclosure 210 includes bathroom wall units 212a, 212b illustratively supported by wall 18 above a base 213 having a drain 215. Translucent shower partitions (not shown) may be supported above the base 213. Mounting channels 217 may receive edges of the shower partitions.

[0048] Each wall unit 212 includes a molded wall panel 222 including a front surface 224, a rear surface 226, a first side edge 228, a second side edge 230, an upper edge 232 and a lower edge 234. The front surface 224 and the rear surface 226 extend between the first and second side edges 228 and 230 and the upper and lower edges 232 and 234. A
first mounting flange 236 is supported by the first side edge 228, and a second mounting flange 238 is supported by the second side edge 230. Similarly, a third or upper mounting flange 239 is supported by the upper edge 232. The first mounting flange 236, the second mounting flange 238 and the upper mounting flange 239 are recessed from the front surface 224 of each wall panel 222.

[0049] First and second wall panels 222a and 222b may be coupled together through a connecting bracket 240. Illustratively, the connecting bracket 240 includes a body 242 having a first pair of arms 244 and a second pair of arms 246. The first pair of arms 244 includes a first inner arm 244a and a second outer arm 244b defining a first recess 248, while the second pair of arms 246 includes a second inner arm 246a and a second outer arm 246b defining a second recess 250. The first mounting flange 236 of the second wall panel 222b is received within the second recess 250, while the second mounting flange 238 of the first wall panel 222a is received within the first recess 248.

[0050] Illustratively, at least one seal 252 is supported by the connecting bracket 240.
For example, at least one seal 252 may be supported by the first pair of arms 244, and at least one seal 254 may be supported by the second pair of arms 246. A first inner seal 252a is illustratively supported by the first inner arm 244a, and a first outer seal 252b is illustratively supported by the first outer arm 244b. Similarly, a second inner seal 254a may be supported by the second inner arm 246a, and a second outer seal 254b may be supported by the second outer arm 246b. As further detailed herein, the outer seals 252b and 254b may be eliminated.
Furthermore, the outer arms 244b and 246b may be eliminated, wherein the inner arms 244a and 246a trap the respective mounting flanges 238 and 236 of the wall panels 222a and 222b against the wall stud 20.

[0051] Illustratively, the body 242 of the connecting bracket 240 is formed of a first material, illustratively a polymer such as a polypropylene. The seals 252 and 254 are illustratively formed of a second material, such as an elastomer or thermoplastic vulcanizate (SantopreneTM TPV). The second material is softer than the first material, such that the seals 252 and 254 frictionally engage and provide effective fluid seals between the mounting flanges 236 and 238 and the body 242 of the connecting bracket 240, while the body 242 of the connecting bracket 240 provides adequate support to the wall panels 222. Illustratively, the first material (e.g., polypropylene) has a hardness or durometer of approximately 75 shore D, while the second material (e.g., TPV) has a hardness or durometer of approximately 50 shore A.
Illustratively, the body 242 of the connecting bracket 240 is co-extruded with the seals 252 and 254 to form a dual extrusion. More particularly, the polypropylene of the body 242 and the TPV of the seals 252 and 254 bond together during the extrusion process.

[0052] While the illustrative embodiment details co-extruded body 242 and seals 252, 254, it should be noted that the body 242 may be formed separately from the seals 252, 254. For example, the body 242 may be molded from a polymer or extruded from aluminum with a pocket to receive separately extruded seals 252, 254. The seals 252, 254 could then be pressed into (or otherwise secured within) the pockets of the body 242.

[0053] In one illustrative embodiment, the first arms 244 extend substantially perpendicular to the second arms 246, thereby defining a corner bracket 240. A
plurality of openings 256 are illustratively formed within the body 242 to receive fasteners (not shown) for securing the bracket 240 to the wall 18. The bracket 240 illustratively extends longitudinally along the full height of the wall panel 222.

[0054] An upper trim or cap 260 may be secured to the upper end of the wall panels 212a and 212b, illustratively through a conventional adhesive. In certain illustrative embodiments, molded cooperating portions of the panels 222 may replace the cap 260.

[0055] In certain illustrative embodiments, an outer corner trim (not shown) may cover the exposed interface or corner joint between the wall panels 222 and extends longitudinally parallel to the corner bracket 240. Alternatively, the corner joint may be sealed with a conventional sealant or caulk.

[0056] A further illustrative corner bracket 240' is shown in FIG. 11 as including many similar features of corner bracket 240 detailed above. The corner bracket 240' includes only inner seals 252a and 254a supported by the inner arms 244a and 246a, respectively. The inner arms 244a and 246a include en.Otrant edges 262 and 264, illustratively curved portions, configured to assist in guiding the mounting flanges 238 and 236 of the wall panels 222a and 222b into the recesses 248 and 250. Additionally, the outer arms 244b and 246b include outer portions 266 and 268 extending beyond the entrant edges 262 and 264 of the inner arms 244a and 246a, and are configured to receive fasteners, such as screws 270 to secure to studs in the wall 18.

[0057] Installation of the shower enclosure illustratively begins by placing the base 213 within the rough-in corner defined by the wall 18. The base 213 is secured to the wall 18 in a conventional manner.

[0058] In one illustrative method of installation, the corner bracket 240, 240' is next secured to the wall 18, illustratively through an adhesive and/or screws 270.
The first wall panel 222a is secured to the bracket 240, 240', illustratively by lubricating the mounting flange 238 with soap or lubricant and then sliding the flange 238 into the recess 248 of the bracket 240, 240'. The wall panel 222a is then secured to the wall 18 by fasteners, such as screws 270 inserted through upper and side mounting flanges 239 and 236. Next, the mounting flange 236 of the second wall panel 222b is inserted within the recess 250 of the bracket 240, 240'. This process is repeated for additional wall panels 222. Sealant or caulk is then illustratively applied along the corner and bottom joints.

[0059] In another illustrative method of installation, a user slides the corner bracket 240, 240' onto the first wall panel 222a and then secures the assembly to the wall 18. More particularly, the flange 238 is slid into the recess 248 of the bracket 240, 240'. Adhesive is applied to the desired wall stud 20, and the wall panel 222a and bracket 240, 240' are pushed into the rough-in corner. The wall panel 222a and bracket 240, 240' are then secured to the wall stud 20 illustratively through screws 270. Holes may be drilled through the wall panel 222a and bracket 240, 240' to facilitate insertion of the screws 270. Next, the mounting flange 236 of the second wall panel 222b is inserted within the recess 250 of the bracket 240, 240'. This process is repeated for additional wall panels 222. The wall panels 222a and 222b are then secured to the wall 18 by fasteners, such as screws 270 inserted through upper and outer side mounting flanges 239 and 236, 238. Sealant or caulk is then illustratively applied along the corner and bottom joints.

[0060] Referring now to FIGS. 12-14, another embodiment of an illustrative corner bracket 300 is shown within a shower enclosure 10. Corner bracket 300 illustratively includes an outer receiver 301 and an insert 303. The illustrative outer receiver 301 includes an outer receiver body 302 having a first trio of arms 304a-304c and second trio of arms 306a-306c. First outer arm 304c and first middle arm 304b define a first outer recess 326 (FIG.
14). Similarly, second outer arm 306c and second middle arm 306b define a second outer recess 328 (FIG. 14).
The first middle arm 304b is angled away from the first outer arm 304c to define a lead-in or enlarged opening for the first outer recess 326, and the second middle arm 306b is angled away from the second outer arm 306c to define a lead-in or enlarged opening for the second outer recess 328.

[0061] First inner arm 304a and second inner arm 306a extend inwardly from first middle arm 304b and second middle arm 306b, respectively. First inner arm 304a and second inner arm 306a define a center recess 330. The inner arms 304a and 306a angle outwardly at open end of center recess 330 to define a lead-in or enlarged channel to assist in receiving the insert 303. The first inner arm 304a, the first middle arm 304b, and the first outer arm 304c are configured to move or flex independently from each other. Similarly, the second inner arm 306a, the second middle arm 306b, and the second outer arm 306c are configured to move or flex independently from each other.

[0062] First middle arm 304b and second middle arm 306b have seals 327, 329 attached thereto respectively. Illustratively, body 302 of outer receiver 301 is formed of a first material, illustratively a polymer such as a polypropylene. Seals 327 and 329 are illustratively formed of a second material, such as an elastomer or thermoplastic vulcanizate (SantopreneTM TPV). The second material is softer than the first material, such that the seals 327 and 329 frictionally engage and provide effective fluid seals between wall panels 340a, 340b and body 302 of outer receiver 301, while body 302 of outer receiver 301 provides adequate support to the wall panels 340a, 340b. Illustratively, the first material (e.g., polypropylene) has a hardness or durometer of approximately 75 shore D, while the second material (e.g., TPV) has a hardness or durometer of approximately 50 shore A. Illustratively, body 302 of outer receiver 301 is co-extruded with seals 327 and 329 to form a dual extrusion. More particularly, the polypropylene of body 302 and the TPV of seals 327 and 329 bond together during the extrusion process.

[0063] While the illustrative embodiment details co-extruded body 302 and seals 327, 329, it should be noted that body 302 may be formed separately from the seals 327, 329. For example, body 302 may be molded from a polymer or extruded from aluminum with a pocket to receive separately extruded seals 327, 329. The seals 327, 329 could then be pressed into (or otherwise secured within) the pockets of the body 302.

[0064] Illustrative corner bracket 300 also includes an inner sealing body 312 that is coupled to body 302. More particularly, a locking device 317 is supported by the outer receiver body 302 and the inner sealing body 312, and is configured to secure the inner sealing body 312 to the outer receiver body 302. Extending into recess 330 are a plurality of raised projections 316a (FIG. 14) extending inwardly from first inner arm 304a and a plurality of raised projections 316b extending inwardly from second inner arm 306a. The plurality of raised projections 316a, 316b of the outer receiver body 302 serve to frictionally engage with a corresponding plurality of raised projections 316c, 316d of the inner sealing body 312 and define locking device 317, as further described below. In one illustrative embodiment, the plurality of raised projections 316 includes a plurality of ridges, teeth, or barbs that are angled along an axis defined by direction A
(FIG. 16). In an alternative embodiment, the plurality of raised projections 316 are perpendicular with respect to the outer surfaces of first and second inner arms 304a, 306a.

[0065] Inner sealing body 312 illustratively includes a first body 336 and a second body 338. Second body 338 of inner sealing body 312 is formed of a first material, illustratively a polymer such as a polypropylene. First body 336 is illustratively formed of a second material, such as an elastomer or thermoplastic vulcanizate (SantopreneTM TPV). The second material is softer than the first material, such that first outer portion 318, second outer portion 320, third outer portion 322, and fourth outer portion 324 of first body 336 frictionally engage and provide effective fluid seals with wall panels 340a, 340b, while locking device 317 of second body 338 of inner sealing body 312 frictionally engages with first and second inner arm 304a, 306a of body 302 as described in further detail below. Illustratively, the first material (e.g., polypropylene) has a hardness or durometer of approximately 75 shore D, while the second material (e.g., TPV) has a hardness or durometer of approximately 50 shore A.
Illustratively, first body 336 of inner sealing body 312 is co-extruded with second body 338 to form a dual extrusion. More particularly, the polypropylene of second body 338 and the TPV
of first body 336 bond together during the extrusion process.

[0066] While the illustrative embodiment details co-extruded first body 336 and second body 338, it should be noted that first body 336 may be formed separately from second body 338. For example, second body 338 may be molded from a polymer or extruded from aluminum with a protrusion to be inserted into a pocket of separately extruded first body 336. Second body 338 could then be pressed into a pocket of first body 336.

[0067] First body 336 includes a first outer portion 318, a second outer portion 320, a third outer portion 322, and a fourth outer portion 324. Outer portions 318, 320, 322, 324 are configured to sealingly engage with wall panels 340a, 340b as described in further detail below.

[0068] Second body 338 of inner sealing body 312 includes spaced apart first arm 332 and second arm 334, which are configured to flex independently relative to each other as they are received within the recess 330. Plurality of raised projections 316c, 316d are supported on the respective outer surfaces of first arm 332 and second arm 334. Plurality of raised projections 316c, 316d of locking device 317 extend outwardly from the outer surfaces of arms 332 and 334 and correspond to the plurality of raised projections 316a, 316b of first inner arm 304a and second inner arm 306a as locking device 317 is moved axially along direction A. In an illustrative embodiment, plurality of raised projections316c, 316d comprise a plurality of ridges, teeth, or barbs that are angled along an axis defined by direction A and form opposing angles with the corresponding plurality of raised projections 316a, 316b. In an alternative embodiment, the plurality of raised projections 316c, 316d are perpendicular with respect to the outer surfaces of first arm 332 and second arm 334 of locking device 317.

[0069] Assembly of the molded wall unit including corner bracket 300 is shown in FIGS.
14-16. As shown in FIG. 14, first outer arm 304c and second outer arm 306c of outer receiver 301 are mounted to a pair of mounting studs 400a, 400b by a pair of fasteners 314, such as screws. In an alternative embodiment, fasteners 314 may also include bolts, nails, and the like.
Fasteners 314 are inserted through recessed pockets 310 along first outer arm 304c and second outer arm 306c. Recessed pockets 310 facilitate easy insertion of fasteners 314, and fasteners 314 ensure that corner bracket 300 does not move when corner bracket 300 is mounted to mounting studs 400a, 400b. In this configuration, recess 326 is substantially parallel with mounting stud 400a, and recess 328 is substantially parallel with mounting stud 400b.

[0070] As shown in FIG. 15, once first outer arm 304c and second outer arm 306c of body 302 are mounted to mounting studs 400a, 400b, wall panels 340a, 340b are coupled to body 302. Wall panel 340a is received within recess 326 (FIG. 14). As an end of wall panel 340a is inserted into recess 326, seal 327 resiliently deforms and allows wall panel 340a to enter into recess 326. Once wall panel 340a is inserted into recess 326, seal 327 applies an outward force onto wall panel 340a thereby cooperating with first outer arm 304c to frictionally engage with wall panel 340a and hold wall panel 340a in place. The interaction between seal 327 and wall panel 340a also provides a fluid tight seal at the interface of the two surfaces. Similarly, second wall panel 340b is inserted into recess 328. As wall panel 340b is inserted, seal 329 resiliently deforms to allow wall panel 340b to enter into recess 328. Once wall panel 340b is inserted, seal 329 applies a force onto wall panel 340b and cooperates with second outer arm 306c to hold wall panel 340b in place. Seal 329 also frictionally engages with wall panel 340b to provide a fluid tight seal at the interfaces of the two surfaces.

[0071] As shown in FIG. 16, once wall panels 340a, 340b are inserted into recesses 326, 328, locking device 317 of inner sealing body 312 is moved along direction A
to be inserted into recess 330. As locking device 317 moves along direction A, first arm 332 and second arm 334 are substantially aligned with a portion of first inner arm 304a and second inner arm 306a.
Specifically, the plurality of raised projections 316c, 316d along arms 332, 334 are substantially aligned with the plurality of raised projections 316a, 316b along first inner arm 304a and second inner arm 306a. Insertion of the second body 338 of inner sealing body 312 within the recess 330 is configured to spread the inner arms 304b and 306b, thereby causing the seals 327 and 329 to make improved sealing contact the wall panels 340a and 340b.

[0072] Also, first outer portion 318 and second outer portion 320 of first body 336 resiliently deform and move inwardly toward first body 336 as they engage with respective portions of wall panels 340a, 340b. As first and second outer portions 318, 320 move inwardly towards first body 336, inner sealing body 312 becomes temporarily thinner (by arms 332 and 334 flexing inwardly) thereby allowing inner sealing body 312 to continue to advance towards recess 330 along direction A.

[0073] As inner sealing body 312 continues to move along direction A, plurality of raised projections 316c, 316d of locking device 317 frictionally engage with plurality of raised projections 316a, 316b of body 302. Inner sealing body 312 is continuously advanced into recess 330 until substantially all of the plurality of raised projections 316c, 316d are frictionally engaged with substantially all of the plurality of raised projections 316a, 316b of first and second inner arms 304a, 306a. The frictional engagement of 316a-316d operates to prevent axial movement of inner sealing body 312 in a direction B, which is defined as the direction opposite of direction A.

[0074] In the illustrative embodiment, frictional engagement of the plurality of raised projections 316a-316d takes place in the form of a ratcheting mechanism where a first raised projection on both of the plurality of raised projections 316c, 316d frictionally engages with a first raised projection on both of the plurality of raised projections 316a, 316b within recess 330 so as to permit movement of inner sealing body 312 along direction A while preventing movement of inner sealing body 312 along direction B (FIG. 16). As additional force is applied onto inner sealing body 312 to further its advancement along direction A, first raised projection of the plurality of raised projections 316c, 316d will disengage from first raised projections of the plurality of raised projections 316a, 316b, and the first raised projections of 316c, 316d will continue to move along direction A.

[0075] The first raised projections of 316c, 316d will then frictionally engage and subsequently disengage with a second raised projection of the plurality of raised projections 316a, 316b. This frictional engagement and subsequent disengagement between the raised projections of 316c, 316d and the raised projections of 316a, 316b will sequentially continue until first raised projections of the plurality of raised projections 316c, 316d reaches the final raised projection of the plurality of raised projections 316a, 316b. In an alternate embodiment, the final raised projections of 316a, 316b are substantially thicker than the other raised projections of 316a, b to prevent subsequent disengagement by the first raised projection of 316c, 316d and continual axial movement along direction A. At this point, substantially all of the plurality of raised projections 316c, 316d of locking device 317 should be frictionally engaged with the plurality of raised projections 316a, 316b of first inner arm 304a and second inner arm 306a.

[0076] Once the plurality of raised projections are frictionally engaged with one another as shown by 316a, 316c and 316b, 316d (FIG.13), locking device 317 is substantially within recess 330, and first outer portion 318 and second outer portion 320 of first body 336 resiliently attempt to return to their original configuration of FIG. 16. By doing this, first outer portion 318 and second outer portion 320 move outwardly from first body 336 and frictionally engage with wall panels 340a and 340b, respectively. This engagement results in two additional seals formed at the interfaces of the first outer portion 318 and the wall panel 340a and the interfaces of the second outer portion 320 and the wall panel 340b.

[0077] In the final configuration of corner bracket 300, third outer portion 322 and fourth outer portion 324 also frictionally engage with portions of wall panels 340a and 340b, respectively. The frictional engagement between third outer portion 322 and wall panel 340a results in an additional seal between first body 336 of inner sealing body 312 and wall panels 340a. Similarly, the frictional engagement between fourth outer portion 324 and wall panel 340b also results in an additional seal between first body 336 of inner sealing body 312 and wall panel 340b. In effect, corner bracket 300 provides multiple fluid tight seals with wall panels 340a, 340b without using caulk or other additional materials for sealing purposes.
In one embodiment, corner bracket 300 provides 3 pairs of seals to wall panels 340a, 340b.

[0078] Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope of the invention as described and defined in the following claims.

Claims (29)

CLAIMS:

1. A bathroom wall unit comprising:
a wall panel formed from a polymer received within a mold defined by a negative impression of a ceramic tile assembly, the wall panel including a front surface, a rear surface, a first side edge, a second side edge, an upper edge and a lower edge, the front surface and the rear surface extending between the first and second side edges and extending between the upper and lower edges; and wherein the wall panel further includes a plurality of linear indentations, a plurality of raised polygonal portions defined between the linear indentations, and a recessed pocket having a rear wall, an upper wall and a lower wall, wherein the polygonal portions are substantially identical to the ceramic tile assembly.

2. The bathroom wall unit of claim 1, further comprising:
a plurality of mosaic tiles received within the recessed pocket;
a flexible substrate supporting the mosaic tiles and coupled to the rear wall of the recessed pocket; and an adhesive securing the flexible substrate to the rear wall of the recessed pocket.

3. The bathroom wall unit of claim 1, further comprising simulated grout within the linear indentations.

4. The bathroom wall unit of claim 3, wherein the simulated grout comprises sand blasted linear indentations.

5. The bathroom wall unit of claim 3, wherein the simulated grout comprises laser etched linear indentations.

6. The bathroom wall unit of claim 1, further comprising a plurality of ribs coupled to the rear surface of the wall panel, the plurality of ribs sized and configured to protrude rearwardly from the wall panel the same distance as the recessed pocket.

7. The bathroom wall unit of claim 1, wherein the wall panel is thermoformed from acrylonitrile butadiene styrene.

8. A method of forming a bathroom wall unit, the method comprising the steps of:
arranging a plurality of ceramic tiles on a support surface;
grouting between the plurality of ceramic tiles to define a ceramic tile assembly;
applying a liquid material over the ceramic tile assembly;
setting the liquid material to a solid material;
removing the ceramic tile assembly from the solid material to define a mold;
applying a polymer to the mold; and molding within the polymer a plurality of linear indentations, a plurality of raised polygonal portions defined between the linear indentations, and a recessed pocket.

9. The method of claim 8, further comprising the step of adhering a plurality of mosaic tiles within the recessed pocket.

10. The method of claim 9, wherein a flexible substrate supports the mosaic tiles and is coupled to a rear wall of the recessed pocket.

11. The method of claim 8, further comprising the step of surface treating the plurality of linear indentations to simulate grout lines.

12. The method of claim 11, wherein the surface treating step comprises sand blasting of the linear indentations.

13. The method of claim 11, wherein the surface treating step comprises laser etching of the linear indentations.

14. The method of claim 8, wherein the molding step comprises thermoforming from acrylonitrile butadiene styrene.

15. A bathroom wall unit comprising:
a first wall panel including a front surface, a rear surface, a first side edge, a second side edge, an upper edge, a lower edge, a first mounting flange supported by the first side edge, and a second mounting flange supported by the second side edge, wherein the first mounting flange and the second mounting flange are substantially identical;
a second wall panel including a front surface, a rear surface, a first side edge, a second side edge, an upper edge, a lower edge, a first mounting flange supported by the first side edge, and a second mounting flange supported by the second side edge;
a connecting bracket including:
a body formed of a first material and including a first pair of arms having a first inner arm and a first outer arm defining a first recess, and a second pair of arms having a second inner arm and a second outer arm defining a second recess, the second mounting flange of the first wall panel received within the first recess, and the first mounting flange of the second wall panel received within the second recess, and a first seal supported by one of the first inner arm and the first outer arm.

16. The bathroom wall unit of claim 15, further comprising a second seal supported by one of the second inner arm and the second outer arm, the first seal and the second seal formed of a second material softer than the first material.

17. The bathroom wall unit of claim 16, wherein the body, the first seal, and the second seal are co-extruded, the body being formed of a polymer, and the first seal and the second seal being formed of an elastomer.

18. The bathroom wall unit of claim 15, wherein the second mounting flange of the first wall panel is recessed from the front surface of the first wall panel, and the first mounting flange of the second wall panel is recessed from the front surface of the second wall panel.

19. The bathroom wall unit of claim 15, wherein the body of the connecting bracket includes a plurality of longitudinally spaced openings to receive fasteners for securing the connecting bracket to a wall.

20. The bathroom wall unit of claim 15, wherein the first wall panel includes:
a recessed pocket having a rear wall, an upper wall and a lower wall;
a plurality of mosaic tiles received within the recessed pocket;
a flexible substrate supporting the mosaic tiles and coupled to the rear wall of the recessed pocket; and an adhesive securing the flexible substrate to the rear wall of the recessed pocket.

21. The bathroom wall unit of claim 20, wherein the wall panel further includes a plurality of horizontal linear indentations, a plurality of vertical linear indentations, and a plurality of raised rectangular portions defined between the linear indentations.

22. The bathroom wall unit of claim 16, wherein the first seal comprises a first inner seal supported by the first inner arm, the second seal comprises a second inner seal supported by the second inner arm, a first outer seal is supported by the first outer arm, and a second outer seal is supported by the second outer arm.

23. The bathroom wall unit of claim 22, wherein the first inner seal is positioned between the first inner arm of the connecting bracket and the second mounting flange of the first wall panel, the first outer seal is positioned between the first outer arm of the connecting bracket and the second mounting flange of the first wall panel, the second inner seal is positioned between the second inner arm of the connecting bracket and the first mounting flange of the second wall panel, and the second outer seal is positioned between the second outer arm of the connecting bracket and the first mounting flange of the second wall panel,

24. The bathroom unit of claim 1, further comprising a mold having the negative impression of the ceramic tile assembly to impart a surface texture of the ceramic tile assembly to the plurality of raised polygonal portions.

25. The method of claim 8, wherein the molding step includes imparting a surface texture of the ceramic tile assembly to the plurality of raised polygonal portions.

26. The bathroom wall unit of claim 15, wherein the first mounting flange of the second wall panel and the second mounting flange of the second wall panel are substantially identical.

27. A bathroom wall unit comprising:
a first wall panel including a front surface, a rear surface, a first side edge, a second side edge, an upper edge, a lower edge, a first mounting flange supported by the first side edge, a second mounting flange supported by the second side edge, a recessed pocket having a rear wall, an upper wall, and a lower wall, a plurality of mosaic tiles received within the recessed pocket, a flexible substrate supporting the mosaic tiles and coupled to the rear wall of the recessed pocket, an adhesive securing the flexible substrate to the rear wall of the recessed pocket, a plurality of horizontal linear indentations, a plurality of vertical linear indentations, and a plurality of raised rectangular portions defined between the linear indentations;
a second wall panel including a front surface, a rear surface, a first side edge, a second side edge, an upper edge, a lower edge, a first mounting flange supported by the first side edge, and a second mounting flange supported by the second side edge;
a connecting bracket including:
a body formed of a first material and including a first pair of arms having a first inner arm and a first outer arm defining a first recess, and a second pair of arms having a second inner arm and a second outer arm defining a second recess, the second mounting flange of the first wall panel received within the first recess, and the first mounting flange of the second wall panel received within the second recess, and a first seal supported by one of the first inner arm and the first outer arm.

28. The bathroom wall unit of claim 27, wherein the body of the connecting bracket and the first seal of the connecting bracket are co-extruded, the body being formed of a polymer, and the first seal being formed of an elastomer.

29. The bathroom wall unit of claim 27, wherein the body of the connecting bracket is extruded with a pocket to receive the first seal of the connecting bracket that is separately extruded, the body being formed of a polymer, and the first seal being formed of an elastomer.